Iveco/FPT GE NEF 45M Generator Set

Tools: Setscrew wrench, Box wrench, Feeler gauge

1. Adjust clearance between rockers and valves using setscrew wrench, box wrench and feeler gauge.
2. Intake valves must be 0.25 ± 0.05 mm and exhaust valves 0.50 ± 0.05 mm.
3. Rotate drive shaft, balance cylinder 1 valves and adjust valves marked by asterisk in the table.
4. For 6 cylinder engines repeat with cylinder 6 balanced.
5. For 4 cylinder engines repeat with cylinder 4 balanced.

⚠ Some motors cannot undergo the passage from 50 Hz to 60 Hz and vice versa; refer to SI 191 1 Service Information.

1. Identify the code of the injection pump from the Stanadyne tag.
2. Act on droop setting adjustment screw, rotating clockwise the number of rotations from the chart.
3. Start the motor and operate maximum and minimum register screws to block accelerator lever.
4. Consider frequency fall from empty to full of about 2 Hz.
5. Block both adjustment screws with lock nuts.

⚠ Coupling mistakes between the actuator hook and the lever of the injection pump can cause motor over speed conditions.

1. Clean external part of the pump, if necessary using solvents.
2. Disconnect wire of stop electro-valve from clamp on pump cover, isolating it.
3. Remove fuel return pipe from connection.
4. Remove three screws of pump cover.
5. Remove cover carefully so dirt won't penetrate inside pump.
6. Remove connection of fuel return pipe and sealing from cover.
7. Reassemble connection and original sealing on the ADC100 electronic actuator.
8. Position actuator on injection pump with highest part slightly tilted upwards.
9. Slide actuator towards rear of pump until U shape hook engages pump lever.
10. Tighten actuator to injection pump using supplied screws.
11. Reconnect fuel return pipe to connection on actuator.

⚠ With switched off motor but still hot the belt can operate without advance notice; wait for motor temperature lowering.

1. Loosen screw and relevant nut on belt stretching bracket.
2. Loosen bolt that fixes alternator to support.
3. Remove worn Poly-V belt from pulleys and driving rollers.
4. Fit new Poly-V belt on pulleys and guide rollers.
5. Stretch POLY-V belt.
6. Lock screw and bolt that fixes alternator to support.
7. Run engine a few hours and check belt stretching.

⚠ If the procedure is not followed, the radiator fluid level will be incorrect.

1. Position container beneath radiator tap to recover the coolant.
2. Open tap and allow all coolant in radiator to flow out.
3. Charge the coolant for the first time.
4. Leave radiator cap open.
5. Start engine and leave running at least a minute so all air is removed.
6. Stop engine and top up.

⚠ At assembly check that adhesive rubber blocks are sound and positioned by the brackets.

1. Remove angular brackets blocking tank inside base by undoing relevant fasteners.
2. Remove tank from its seat.

⚠ Engine oil is highly polluting and harmful; protect skin and eyes and dispose of properly.

1. Check with engine disconnected and possibly cool.
2. Draw off flexible rod from its slot and check level within etched tags of minimum and maximum.
3. If difficult, clean rod with clean cloth, put back in slot, draw it off again and check level.
4. If level close to minimum tag, fill through upper top or lateral top with tops and rod removed.

⚠ Don't smoke and don't use free flames. Avoid breathing vapours from filter.

⚠ After filters replacement the supply equipment deaeration must be carried out.

Tools: 99360076

1. Drain fuel inside filter by operating water release screw; collect fuel in container.
2. Unscrew cartridge using 99360076 tool.
3. Collect eventual fuel inside filtering cartridge.
4. Clean gasket seat on support and oil slightly gasket on new cartridge.
5. Screw manually new cartridge until gasket is completely on its seat.
6. Tighten through 99360076 tool at 10-5 Nm (F4GE) or 10 to 15 Nm (F4AE).

⚠ Wear protection gloves because of high motor service temperature.

⚠ Oil filter contains about 1 kg of engine oil; place a proper container.

Tools: 99360076

1. Place container for oil under the pan connected with drain plug.
2. Unscrew plug, take out dipstick and inserting plug to ease downflow.
3. After complete drainage screw plug and carry out clean oil filling.
4. Check level through dipstick up to maximum level notch.
5. Replace filtering cartridge using 99360076 tool; screw manually until gasket contacts support.
6. Tighten by means of 99360076 tool of three fourth turn.
7. Operate motor some minutes and check level again, topping up if necessary.

⚠ Check integrity of rubber-type blocks in supports of pipes and electrical connections.

1. Disconnect electrical system by detaching cables from battery.
2. Disconnect positive and negative cables from clamps and starter motor.
3. Remove fan safety grilles.
4. Place container under cock, disconnect and remove coolant pipes with sleeves.
5. Block radiator, disconnect brackets and nuts, remove radiator.
6. Disconnect diesel pipes from engine and tank.
7. Disconnect electrical connection of diesel level signal and earth.
8. Disconnect air hose from turbocharger and remove air cleaner.
9. Fit lifting tool on engine hooks and keep under tension.
10. Remove fixing nuts from four supports of engine/generator assembly.
11. Separate engine/generator assembly from crankcase.

⚠ When removing pipe pay attention not to damage cooling unit air ducts.

⚠ Make sure rods have the same length to lift the soundproofing unit along the vertical axis.

1. Operate from control board side and disconnect electric connection from stop button.
2. Move back exhaust pipe cover to reach stop collar, loosen fastening screw.
3. Loosen covering panel fastening nuts from exhaust pipes side and remove panel.
4. Remove pipe from its seat.
5. Loosen soundproofing unit fastening screws along perimeter.
6. Secure hooks with chain catches in slots and lift soundproofing unit with hoisting device.

⚠ Be careful that nothing falls into the injection pump.

⚠ Pay attention to position of the isolating element and assembling order of nuts, washers and components.

Tools: Joint tool supplied in ETR kit

1. Remove cover of injection pump loosening three fixing screws and washers.
2. Remove entire cover of the electro-valve pulling it upwards perpendicularly.
3. Remove electro-valve from the cover.
4. Assemble new electro-valve on injection pump cover using appropriate kits (12V-ETR, 24V-ETR, 12V-ETSO, 24V-ETSO).
5. Tighten fixing nuts of electro-valve to cover.
6. Use joint tool to position electro-valve arm and reassemble cover.